Article with elastic distribution and system and method for making same

ABSTRACT

A method is described for making an elasticized absorbent article having a waist opening and a pair of leg openings. First, multiple distributions of elastics are applied on a moving material sheet to form a moving web of an elastic composite. Then, each of a core section and a second material sheet is periodically applied onto the moving web to define a finished web of discrete elastic composite bodies. In subsequent steps, discrete absorbent pants articles are shaped from the finished web.

The present application is a Continuation application of U.S.application Ser. No. 14/946,528 filed on Nov. 19, 2015 (now allowed),which is a Continuation application of U.S. application Ser. No.13/200,100 filed on Sep. 16, 2011 (now U.S. Pat. No. 9,205,003), whichclaims the benefit of U.S. Provisional Application Ser. No. 61/403,488,filed on Sep. 16, 2010, which disclosure is hereby incorporated byreference for all purposes and made a part of the present disclosure.

BACKGROUND OF THE INVENTION

The present invention relates generally to an elastic composite and adisposable absorbent article incorporating an elastic composite. Theinvention also relates to elastic composite webs, systems, and methodssuitable for making the same. Aspects of the invention are particularlysuited for, or related to, disposable absorbent articles such as babydiapers, training pants for infants and young children and adultincontinence diapers and pants. Specific embodiments of the inventionmay provide a web of elastic composite, an elastic composite or body, orelastic distribution patterns within these products, which, in turn, mayimprove the product's fit and comfort, its support and sealingcapabilities, enhance the cost and manufacturability of the productand\or enhance the aesthetic qualities of the product.

Disposable absorbent articles contemplated by the invention includetraining pants, pull-on diapers, disposable underwear, and adultincontinence garments. As for training pants, these garments are used byyoung children to facilitate a child's transition from using diapers towearing regular underpants (i.e., during toilet training). Trainingpants and other disposable pull-on pants have closed sides such that theuser or caregiver raises the garment about the user's legs to wear thegarment and slips the garment downward about the user's legs to take itoff. These articles and garments are collectively referred to herein as“absorbent pants” or “pants products.”

Elastic members may be incorporated into different parts of an absorbentgarment. For example, elastic members may be positioned longitudinallyalong a diaper, generally outboard of the absorbent core to effect aseal around the buttocks, legs, or both of the users. In addition,several elastic members (e.g., in the form of elongated elastic threadsor strands) may be positioned laterally throughout the waist regions(including the side waist regions) of an absorbent garment. Theresulting elastication allows the garment to stretch when it is put onand when it is worn. The elastication allows the garment to accommodatevariations in waist size and leg size of the user, while fitting snuglyabout the waist and legs.

When elastic members are incorporated into a part or area of anabsorbent garment, that part or area typically becomes a distinct,functional component of the garment. These elastic components includethe side panels or ear portions, the waistband, and fastening tabs. Duein part to its multi-component construction, elastic composites mayrequire a dedicated sub-process for manufacture which must beaccommodated by the greater garment manufacturing process.Alternatively, the elastic composite may be manufactured independentlyor simply, manufactured in a separate sub-process detached from thecentral garment manufacturing system. In either case, a source of theelastic composite may be provided as input to the garment manufacturingprocess.

In most applications, the elastic composite has a significant impact onthe fit and sealability of the garment, as well as the generalappearance and construction quality of the garment. The design andconstruction of the elastic composite can also represent a significantportion of the cost of manufacturing the garment. It is, therefore,desirable to provide a functionally and/or aesthetically improvedelastic composite or a cost effective system and method of making theelastic composite.

U.S. Pat. Nos. 7,462,172 and 7,361,246 provide background information onelastic composites (and the manufacture of such composites) of a typerelevant to the present invention. Accordingly, these patentpublications are also hereby incorporated by reference and made a partof the present disclosure, but only to the extent that incorporatedsubject matter provides background information and/or exemplarycomposites and processes suitable for use on, or with, the presentinventive composites, systems, and methods. Thus, the incorporatedsubject matter shall not serve to limit the scope of the presentinvention. It should be noted that while these prior patent publicationsprovide some discussion on making elastic composites and thenincorporating same into absorbent articles, the present invention is, inone respect, more particularly directed to providing an improved systemand method of making an elasticized absorbent article and/or a web ofelastic composite bodies. More specifically, one directive of thepresent invention is to provide a method and system, whereby and whereinthe elastic composite and its formation are seamlessly integrated intothe method of making the article and into the elasticized articleitself.

SUMMARY OF THE INVENTION

For purposes of the present description, the terms “elastic composite”,“elastic composite body”, and “elasticized article” refer to amulti-layer or multi-component construction that incorporates anelastomeric material(s) or elastic member(s). In this construction, aplurality of elastic members, such as threads or strands, are connectedto or disposed adjacent one or more materials, e.g., backsheet andtopsheet. In this way, the elastic members impart elasticity to theconnected or adjacent layers and thus, to that part of the garment orarticle. Such an elastic structure may be a distinct attachablecomponent of the garment or article, or may be a distinct portion orsection of the garment body article or a larger, unitary component ofthe garment.

Further, as used herein, the term “web” refers to an extended,conveyable sheet or network. The term “substrate” refers to a supportingweb, sheet, or layer, such as a web or layer of backsheet onto whichelastics adhere or are otherwise supported. Further, a web may be of anelastic composite and/or provide a plurality or series of discreteelastic composite bodies. In embodiments described herein, such elasticcomposite bodies may be separated from the web to form the basis of adisposable absorbent article such as a diaper or absorbent pants.

In one aspect of the present invention, an elasticized disposableabsorbent article is provided in the form of absorbent pants. Theabsorbent pants include an elastic composite body, a backsheet, atopsheet, an absorbent core between the backsheet and topsheet, andmultiple elastic distributions between the topsheet and backsheet.Furthermore, the elastic composite body has a front end edge, a rear endedge, and two lateral side edges each having a top segment, a bottomsegment, and a non-linear cut-out section therebetween. The absorbentarticle also includes a waist opening defined by the end edges, a pairof leg openings each defined, at least partly, by the cut-out section ofone of the lateral side edges, and a pair of side seams each defined bya joining of the top and bottom segments of one of the lateral sideedges. The elastic distributions are substantially joined at the sideseams to form a substantially annular elastic region about each legopening.

In further embodiments, the elastic composite body also includes a pairof elastic distributions joined at the side seams to form asubstantially annular elastic region about the waist opening.Preferably, the elastic composite body further includes a pair ofelastic distributions each extending across the composite body andsubstantially joining the other at the side seams to form thesubstantially annular elastic region about the leg opening.

In another aspect of the invention, a method of making elasticizedabsorbent pants preferably commences with applying multipledistributions of elastics on a moving material sheet to form a movingweb of an elastic composite. Each one of a core section and a secondmaterial sheet is periodically applied onto the moving web to define afinished web of discrete elastic composite bodies. The steps leading todelivery of a finished web of discrete elastic composite bodies may bereferred to as the step of joining the elements or layers of the targetelastic composite web. In a subsequent step, discrete absorbent pants orarticles are shaped from the finished web. The shaping step may includejoining each of a bottom half portion and a top half portion of eachcomposite body to form a plurality of substantially continuous elasticdistributions in the elastic composite body. In a further embodiment,the joining step forms annular elastic regions about a waist openingand/or each of a pair of leg openings. In further embodiments, thejoining step is preceded by the step of folding the finished web along alongitudinal centerline and the joining step includes sealing the twohalf portions along two side seams to define at least a waist opening.In another embodiment, the joining step is preceded by the step ofperiodically cutting a cut-out section of the finished web at a locationadjoining adjacent elastic composite bodies such that, after the joiningstep, each lateral boundary of the elastic composite body consists of alateral side seam and the cut-out section. The shaping step furtherincludes severing the finished web along a cut line bisecting thecut-out sections. In a more preferred embodiment, the joining stepprecedes the severing step so that the severing step immediatelyproduces elastic absorbent pants having a waist opening, a pair of legopenings, and multiple continuous elastic distributions extendingthrough two lateral seal lines or side seams.

According to another aspect of the invention, a method of making anelastic composite web, from which elastic composite bodies of absorbentpants may be separated, commences with the steps of conveying acontinuous web of material sheet and applying multiple continuousdistributions of elastics on the moving web to form a web of elasticcomposite, the elastic distributions generally extending in the machinedirection. The method also entails periodically applying a core sectionon the moving elastic composite web and, then, continuously applying atop material sheet on the web including the core sections. In the stepof applying continuous distributions of elastics, at least two periodicdistributions of elastics are established on the moving web by varyingthe lateral position of the distribution of elastics as thedistributions are advanced in the machine direction toward the movingweb of elastic composite. In further embodiments, the step of applyingthe continuous distributions includes periodically varying the lateralposition of the elastic distribution prior to engagement with thematerial sheet and further yet, periodically varying the lateralposition to establish two elastic distribution patterns on the movingweb of elastic composite that periodically trace an annular elasticregion. In further embodiments, the method includes a step ofperiodically severing one or more of the elastic distributions so as toprelocate gaps in the elastic distribution on the moving web of elasticcomposite. In further embodiments, each of the elements or layers of aweb of elastic composite bodies is delivered in-line or in the machinedirection, and further, at or about a joining station or mill of thesystem.

In another aspect of the present invention, a system and process areprovided for delivering a web of elastic composite bodies. The systemand process provides a central forming region or joining mill thatreceives all of the elements or layers of the target elastic compositeand joins these elements in accordance with a specific sequence.Preferably, all of such elements are inputted into the mill and receivedin the machine direction. The output of the joining step is a web ofelastic composite bodies that may be further manipulated to achieve aseries of disposable absorbent articles. Post-joining steps may includefolding, sealing, and/or severing of the elastic composite bodies.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the features and advantages of the presentinvention may be understood in more detail, a more particulardescription of the invention briefly summarized above may be had byreference to the embodiments thereof which are illustrated in theappended drawings that form a part of this specification. It is to benoted, however, that the drawings illustrate only various exemplaryembodiments of the invention and are therefore not to be consideredlimiting of the invention's scope as it may include other effectiveembodiments as well.

FIG. 1A is a simplified illustration in isometric view of a disposableabsorbent article according to the present invention;

FIG. 1B is a cross-sectional view an elastic composite or elasticcomposite web according to the present invention;

FIG. 2A is a simplified diagram in side view of a system or apparatusfor making an elastic composite or elastic composite web according tothe present invention;

FIG. 2B is a plan view of the system in FIG. 2A;

FIG. 2C is a graphical diagram of an exemplary periodic functionreflecting directive lateral motion by elastic guides in FIGS. 2A-2B toproduce a dual elastic distribution pattern on an elastic composite web,according to the present invention;

FIG. 3 is a simplified illustration of an elastic composite webaccording to the present invention;

FIG. 4 is a simplified illustration of a web-based process for makingthe disposable absorbent article in FIG. 1, according to the presentinvention;

FIG. 4A is a simplified illustration of a web-based process for makingan alternative disposable absorbent article, according to the presentinvention;

FIG. 5 is a simplified illustration of a web-based process for making adisposable absorbent article, according to an alternative embodiment ofthe present invention;

FIG. 6 is a simplified schematic of system for making the disposableabsorbent article in FIG. 1, according to the present invention;

FIG. 7 is a simplified illustration of an elastic composite web employedin a web-based process for making a disposable absorbent article,according to the present invention;

FIG. 7A is a simplified illustration in isometric view of a disposableabsorbent article according to an alternative embodiment of the presentinvention;

FIG. 8 is a simplified illustration of yet another alternative elasticcomposite web according to the present invention;

FIG. 8A is a simplified illustration in isometric view of anotherdisposable absorbent article according to an alternative embodiment ofthe present invention;

FIG. 9 is a simplified illustration of yet another alternative elasticcomposite web according to the present invention;

FIG. 9A is a simplified illustration in isometric view of anotherdisposable absorbent article according to yet another alternativeembodiment of the present invention;

FIG. 10 is a simplified schematic representation of a system for makinga disposable absorbent article according to the present invention;

FIG. 10A is a cross-sectional view of a web of elastic composite bodiesaccording to the present invention;

FIG. 10B is a cross-sectional view of an alternative web of elasticcomposite bodies according to the present invention;

FIGS. 11A-11B are simplified illustrations of an elastic composite body,according to yet another alternative embodiment of the presentinvention;

FIG. 12A is a simplified illustration of an elastic composite web havingdual elastic distribution patterns applied thereon, according to anembodiment of the present invention;

FIG. 12B is a graphical diagram of a periodic function reflectingdirective lateral motion by elastic guides to produce the dual elasticdistribution patterns on the elastic composite web of FIG. 12A;

FIG. 13 is a flowchart diagram for a method of making an elasticizedabsorbent article, according to one embodiment of the present invention;

FIG. 14 is a flowchart diagram for a method of making an elasticcomposite web, according to an embodiment of the present invention;

FIG. 15A is a simplified illustration in isometric view of a disposableabsorbent article according to an alternative embodiment of the presentinvention;

FIG. 15B is a simplified illustration of a web of elasticized compositebodies from which the article in FIG. 15A is derived;

FIG. 16A is a simplified illustration in isometric view of a disposableabsorbent article according to an alternative embodiment of the presentinvention;

FIG. 16B is a simplified illustration of a web of elasticized compositebodies from which the article in FIG. 16A is derived;

FIG. 17 is a simplified illustration of a system and process of applyingelastic distributions on a web of elastic composite bodies, according tothe present invention; and

FIG. 18 is a simplified illustration of an elasticized core structureachievable by the system and process according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention will now be described more fully with reference tothe accompanying drawings, which illustrate various exemplaryembodiments. The invention may, however, be embodied in many differentforms and should not be construed as being limited by the illustratedembodiments set forth herein. Rather, these embodiments are provided sothat this disclosure will be thorough as well as complete and will fullyconvey the scope of the invention to those skilled in the art and thebest and preferred modes of practicing the invention. For example, manyof the exemplary descriptions provided herein are concerned withtraining pants for infants and young children. Aspects of the inventiondescribed may, however, be equally applicable to designs for and themanufacture of, baby diapers, adult incontinence products and othersimilar products.

FIG. 1A illustrates a first embodiment of the present invention, in theform of a disposable absorbent training pants 101. The upright absorbentpants 101 is formed from an elasticized composite body 136 with a firstor front half portion rotated about a symmetrical line to join asubstantially identical second or rear half portion. The two halfportions are joined at a pair of sealed side seams 130. Each side seam130 consists of a first or bottom segment of a side edge 106 joined to asecond or top segment of the same side edge 106 (as will be furtherexplained below). The resultant absorbent pants 101 has a frontlongitudinal waist edge 102, a rear longitudinal waist edge 103, and thepair of sealed side seams or seals 130 each on a lateral side of theabsorbent pants 101. To facilitate the present description of theinvention, the pants body 136 is sometimes described as having an upperwaist region 124 and a lower waist, leg, and crotch region (lower region126). The absorbent pants configuration 101 is also provided with afluid distribution and storage construction or absorbent core 105 on theinside of the pants 101 and about a crotch region 134. In one aspect ofthe invention, the forming of the two lateral side seals 130 immediatelycreates the absorbent pants configuration 101. This absorbent pantsconfiguration 101 includes a waist opening 132 defined by the joining ofthe two waist edges 103 to complete a continuously encircling waistedge. The pant configuration 101 further includes two leg openings 104formed by the joining of the half portions (as will also be furtherexplained below).

The pants configuration 101 also includes the lateral side seams 130.The side seams 130 may be provided by a permanently bonded seal or arefastenable seal. A permanent side seal may be achieved, for example,through the use of adhesive bonding, thermal bonding, ultrasonic bondingor any other suitable bonding mechanism. A refastenable side seal may beachieved through the use of adhesives, hook and loop materials or otherrefastenable mechanisms.

To enhance the comfort and fit of the absorbent article, as well as itscapacity to contain fluid and minimize the occurrence of leakage offluid through the waist and leg openings 132, 104, the disposableabsorbent article 101 is provided with strategically-placed elastomericmaterials 120. In a preferred embodiment, these elastomeric materialsconsist of strands or yarns of elastic thread such as natural rubber,latex strands or synthetic elastomers such as Lycra or Spandex yarns.Other suitable elastomeric materials include, but are not limited to,stretchable elastomeric films, elastomeric ribbons, elastomericnonwovens and elastomeric adhesives. For purposes of this description,any discussion of the elastomeric materials will be confined to the useof elastomeric strands or yarns, which may referred to as elasticstrands or elastics. It will become apparent, however, that theseelastomeric materials may be readily substituted with many other typesof elastomeric material.

The absorbent pants 101 in FIG. 1 incorporate multiple distributions ofelastic strands 120 in the upper waist region 124 and in the lowerwaist, leg and crotch regions (lower region 126). These distributions ofelastic strands render the composite body 136 with strategicallylocalized and advantageously configured elasticity. Upon sealing of theside edges 106, this feature translates directly and readily to theresultant absorbent pants 101 and ultimately, to the pants 101 as wornby the user. Accordingly, the pants 101 of the invention may be referredto as an elasticized disposable absorbent article 101. To elaborate,each of the elastic distributions in the absorbent pants 101 define asubstantially annular area or region of elastics or elasticity. In theupper waist region 124, a set or distribution 110 of the elastic strands120 is arranged generally circumferentially about the waist opening 132and just below the joined waist edges 102, 103, and thus, encircles thewaist of the user. Preferably, the elastic strands 120 are mutuallyspaced apart and generally parallel with the waist edges 102, 103.Accordingly, the absorbent pants 101 is equipped with a particularlyadvantageous annular region of elastic and elasticity snugly encirclingthe entire waist of the user and, acting therewith, to effectively sealthe waist opening 132. In the lower region 126, multiple distributionsof elastic strands 120 extend substantially completely about the legopenings 104 and the crotch region 134. One set or distribution 111 ofelastic strands 120 encircle the leg opening 104 and forms anelasticized annular area or region thereabout. A third annular area orregion of elastics is generally positioned centrally in the crotchregion 134.

The elastic annular regions about the waist opening and the leg openingsare advantageously maintained substantially all the way around thesealing subject (i.e., the potential opening between the waist and thewaist edge 102,103 and the potential openings between the thigh and thecircular side edge of the article 101). Moreover, the strength anddirection of the elastic forces are maintained generally uniform aboutthe openings. A more effective and more reliable seal is achievedbecause all potential leakage points around the opening are addressed.Uniformity in the elasticity about the waist or thigh also helps toprevent uneven fit, which can lead to a poor seal. Notably, the elasticdistributions 110, 111 in the composite body 136 extend substantiallyall the way from one side edge to the opposite side edge (as explainedbelow) and, upon formation of the pants configuration 101, extendsubstantially continuously (without ends) about the article 101. Itshould be understood, however, that the elastics of the annular regionsdo not necessarily have to touch or overlap. It is sufficient for theends of elastics to be proximate to opposing ends so as to effectgenerally uniform elasticity about the sealing subject or edge,substantially similar to an actual ring of elastic placed therebout.

It should be noted that the elastic strands 120 about the leg opening104 may overlap into the crotch region 134. It should also be noted thatthe elastic strands 120 in the upper and lower regions 124, 126 are notnecessarily mutually exclusive and elastic strands in one region mayoverlap and intersect elastic strands in the other region.

In one aspect of the present invention, the disposable absorbent article101 having one or more annular regions of elastics or elasticity may bemade utilizing a single, unitary elastic composite body 136 (or prior tomaking the pants configuration 101, simply elastic composite 136). FIG.1B is a cross-sectional view of an exemplary elastic composite 136specifically for the absorbent pants 101 of FIG. 1B. Among other things,this view describes the multiple distributions of the elastic strands120 in the elastic composite 136 utilized in the absorbent pants 101according to the present invention. The elastic composite 136 has afirst or bottom edge 102 and a second or top edge 103 (which ultimatelydefine the waist edges 102, 103 in the pants configuration 101). Thecomposite 136 also has an outer, fluid impermeable backsheet layer 107,an optional intermediate layer 108, a fluid distribution and storageconstruction or core 105 and a fluid permeable topsheet 109. The fluidimpermeable backsheet layer 107 may be selected from a range ofmaterials that include hydrophobic, fluid impermeable nonwovenmaterials, breathable and non-breathable polyethylene films or laminatesof these materials. The optional intermediate sheet layer 108 may alsoinclude hydrophobic, fluid impermeable nonwoven materials, breathableand non-breathable polyethylene films, and laminates of said materialsor other suitable materials. As shown in FIG. 1B, the two sheet layers107, 108 help retain the elastic distributions 110, 111 in place,although, in some embodiments, the elastic distributions are adheredonly to the surface of the backsheet layer 107. The fluid distributionand storage construction or absorbent core 105 may be composed ofnonwoven materials, aperture films, tissue, cellulose fluff pulp,superabsorbent polymer particles or fibres or any other materials thatcan be utilized to distribute and absorb the fluid and solid insultspassed into the article when it is used. Furthermore, fluid permeabletopsheet 109 may comprise a hydrophilic, fluid permeable nonwoven web oran apertured material.

For the absorbent pants 101 of FIG. 1, the exemplary elastic composite136 reveals a first distribution 110 of elastic strands 120 directedalong each of the first edge 102 and the second edge 103. In thisembodiment, a grouping of six spaced apart strands 120 is generallybunched together along the edges 102, 103, while three individualstrands 120 are located inwardly of these strands 120. The spacingbetween the three individual strands 120 is wider than that of the firstsix strands 120. This spacing of strands 102, 103 corresponds with thespacing of the strands 120 in the upper region 124 of the disposableabsorbent article 101 of FIG. 1A which concentrates elasticity near theedges 102, 103. The elastic composite 136 also features the two otherdistributions 111 of elastic strands 120. Two distributions 111 of fivestrands 120 each are located inwardly from the two outside distributions110, as shown in FIG. 1B. As will be further described below, these twodistributions 111 correspond with the elastic distributions 111 aboutleg openings 104 and in the crotch region 134 of the disposableabsorbent article 101.

The simplified illustrations of FIGS. 2A and 2B describe a system 150and method for making a web 240 of the elastic composite 136. Morespecifically, the system 150 and method are utilized for incorporatingthe desired elastic distributions 110, 111 described above in an elasticcomposite 136 and in a composite web 240 (and ultimately, in anabsorbent article 101), according to the invention. The illustratedmethod provides an initial sub-process in making the elastic composite136 and the disposable absorbent article 101 in FIG. 1. FIG. 4illustrates the subsequent and remaining stages in this method. BothFIGS. 3 and 4 depict a unitary elastic composite web 240 that isparticularly suited for making disposable absorbent articles 101. Aswill be described, the composite web 240 can contain and present fourcontinuous, machine-directioned distributions of elastic strands thattrace a specific, advantageous pattern. At least two of thedistributions are described by a periodic function featuring a troughand a summit. The other two distributions are preferably maintainedalong a direct path.

Referring now to FIGS. 2A and 2B, the inventive system 250 and methodconvey, append, and manipulate an elastic composite web 240 in asubstantially linear process and in the machine direction. For purposesof description, the web 240 is referred to as having a first or bottomedge 202, a second or top edge 203 spaced apart from the first edge 202in the cross-machine direction and generally parallel therewith, across-machine width defined between the two edges 202, 203, and alongitudinal centerline YY. In some descriptions, the cross-machinedirection across the web 240 and components supporting the inventive web240 may be referred to as a lateral direction, while the machinedirection may be described as corresponding to a longitudinal direction.Preferably, the elastic composite web 240 is advanced at a uniform rateof speed in the longitudinal or machine direction.

In a preferred embodiment, the method initially requires the separate,continuous conveyance of each of six elements of the elastic composite136 to a joining mechanism such as a nip roller 218 (see e.g., FIG. 2A).These elements include a first material sheet 212, a second materialsheet 213, a first set 210 a of pre-tensioned elastic strands along thetop edge 203, and a second set 210 b of pre-tensioned elastic strandsalong the bottom edge 202. The first and second sets 210 a, 210 b ofelastics strands are aligned in mutually parallel alignment but spacedapart specifically according to a pre-determined arrangement. In thisspecific embodiment, the first and second sets 210 a, 201 b are mirrorimages of one another. Additionally, two other sets 211 a, 211 b ofpre-tensioned elastic strands are conveyed along a machine directionlaterally inwardly of the first and second sets 210 a, 210 b ofpre-tensioned elastic strands. As best shown by FIG. 2A, both the firstand second sets 210, 211 of elastics are preferably introduced andconveyed toward the nip roller 218 along the horizontal plane of the web140. The two inwardly sets 211 a, 211 b of elastics are also introducedon the same web plane. The two material webs 212, 213, are on the otherhand, preferably initiated from generally above and below the web plane,respectively (hence, sometimes referred to as upper and lower materialwebs or sheets).

The elastic strands may be received in a tensioned state by means of anysuitable feeding and tensioning device positioned upstream of thisprocess (not shown). The initial lateral positions of the elasticstrands, as well as the spacing between adjacent elastic strands, areinitially fixed by elastic guides 215. These fixed elastic guides 215are mounted on two rods 219, as shown in FIGS. 2A and 2B. The elasticguides 215 typically comprise rollers, eyelets or any other suitablemeans for conveying and guiding the pre-tensioned elastic strands. Asecond set of elastic guides 216 a, 216 b are mounted on movable rods221 downstream of the fixed rods 219. Each of these two movable elasticguides 216 a, 216 b engages one of the two inward sets 211 a, 211 b ofelastic strands. Preferably, the movable rods 221 and movable guides 216a, 216 b are positioned above and below the web plane, respectively.Thus, while a first set 211 a of elastics is introduced along the webplane, it is directed slightly above the web plane a short distanceafter introduction. Similarly, the other set 211 b is directed slightlybelow the web plane after introduction. This adjustment occurs beforethe two sets 211 a, 211 b of elastics are engaged by conveying means 217and advanced to the nip roller 218.

It should be noted that the specific components of the system 250 shownin the Figures may be substituted with other suitable means orcomponents. For example, in alternative systems, stationary guides oreyelets may be mounted on a fixed frame. Further, the movable guides maybe mounted or associated with mechanical arms, cam systems, and othersuitable mechanisms.

The sets 210 a, 210 b of elastic strands are distributed in a generallyparallel alignment toward the nip roller 218. These elastic strands areanalogous with the distribution 110 of elastic strands present in theupper waist region 124 of the absorbent article 101 in FIG. 1 and aredistributed in parallel relationship with the top and bottom edges 202,203 composite web 240. For the absorbent pants 101 of FIG. 1, thearrangement of the sets 210 a, 210 b of elastic strands must beidentical. Other article designs may be provided, however, wherein thearrangements are not identical and one set may include more elasticstrands than the other set. Also, the spacing and concentration of theelastics may, in other designs, differ to achieve a specific function oraesthetic attribute. Although such designs may deviate from thepreferred arrangements for annular elastic regions, as described above,it is expected that such alternate designs will not deviate completelyand that some aspects of the preferred designs will be retained (inaccordance with the invention).

The moveable elastic guides 216 a 216 b are configured to move in adirection orthogonal to the machine direction of the web 240 and serveto change and direct the placement of the sets 211 a, 211 b of elasticstrands into the nip roller 218 and adjust the lateral spacing of theelastic strands. Accordingly, the two inward sets 211 a, 211 b ofelastics may be referred to as variable (as opposed to “fixed”) sets ofelastics. By vertically spacing the two variable sets 211 a, 211 b ofelastics (as described above), the two sets 211 a, 211 b can movelaterally without interference from the other. In this embodiment, forexample, the two sets 211 a, 211 b of elastics laterally cross so that abottom set of elastics arrives at the nip roller 218 as the top side setwhile the other set becomes the bottom side set.

In a preferred embodiment, the elastic guides 216 a and 216 b aremounted on a reciprocating mechanism such that the elastic guides arecontinually reciprocating in a lateral direction (orthogonal ortransverse to the machine direction of the process). The guides 216 a,216 b may be carried on the same continuous belt or track and movetogether at all times. In other embodiments, the guides 216 a, 216 b maybe driven independently of one another, particularly if the pattern ofon elastic distribution is greatly independent of the other. Suitabledriving mechanisms can include a cam based mechanism, a servo drivenmechanism or a hydraulic mechanism. Preferably, the motion of theelastic guides 216 a and 216 b is described by a periodic function, inwhich a relative displacement of the elastic (or elastic guide) is afunction of time (or a length of the web) plus a discrete increment (P,period). This displacement function expresses the periodic shape orpattern of the distributed elastics.

The graphical illustration of FIG. 2C describes an exemplary periodicfunction reflecting the lateral displacement (D) of the movable guides216 a, 216 b over a period of time (P) (which is proportional to thewidth of the elastic composite 136 relative to machine speed). The twoseparate functions f1, f2 show the relative lateral movement of theguides required to produce the dual elastic distribution patterns on theweb. As shown by the graph, the two elastic guides necessarily crosstwice during each period. The multiple crossings translate to thegeneration of a series of elastic annular regions on the composite web,or at least two annular regions per period (P) or elastic composite body136.

The upper and lower sheets 212, 213 are also directed by conveyancemeans 217 toward the web plane and then to nip roller 218. Thus, the twosheets 212, 213 and the four sets 210, 211 of elastics arrivesubstantially together at the nip roller 218. The upper and lower sheets212, 213 served to sandwich, entrap and hold the elastic strands inposition after passing through the nip roller 218. The resultant web 240of elastic material and material webs is secured using any suitablebonding means which include, adhesive, ultrasonic or thermal bonding(not shown). In the case of adhesive bonding, the adhesive could beapplied to the upper and lower sheets 212, 213 or applied directly tothe sets 210, 211 of elastic strands at any point prior to the elasticstrands and upper and lower sheets meeting and combining at the niproller 218.

FIG. 3 illustrates the continuation of the system 250 and method ofmaking the disposable absorbent article 101 illustrated by FIGS. 2A, 2B.The system 250 and method of FIGS. 2A and 2B output an elastic compositeweb 240 that includes an upper sheet 212, a lower sheet not shown, butdirectly underlying the upper sheet 212, and distributions E10, E11 ofelastic strands across the cross-machine direction width of the web 240.The two variable distributions E11 of elastic strands disposed in themiddle are directed by means of the periodic, lateral motion of theelastic guides 216 a, 216 b in FIG. 2 (and its periodic function), whichin this example, result in a sinusoidal pattern. The pattern may also bedescribed as a series of annular elastic regions O1 or areas formed bythe troughs and valleys of the two variable distributions E11 ofelastics. Other linear and non-sinusoidal patterns may be produced bythis process; but, for the purposes of this exemplary description, thesinusoidal pattern is employed. One set 211 a of elastics is distributedin a first sinusoidal pattern E11 and are overlapped with the elasticsof the second set 211 b which are distributed in a second sinusoidalpattern E11. In this example, the first and second sinusoidal patternsare mirror images of each other. The two distributions E11 also define aregion Ix at which one set overlaps and intersects the other. The degreeto which the elastic strand patterns overlap can be measured and is,hereafter, described as the variable “X”. The wavelength of thesinusoidal pattern can also be measured and is hereafter recorded as thevariable “Y”. Both variables “X” and “Y” are process parameters that maybe adjusted by changing various process parameters such as machinespeed, reciprocation speed and reciprocation depth.

FIG. 4 illustrates a process or conversion step for further modifyingand then converting the elastic composite web 240 of FIGS. 2 and 3 intothe disposable absorbent article 101 in FIG. 1A. As shown in FIG. 4, thesub-process proceeds downstream from left to right whereby the initialstep may be described as receiving an output (the elastic composite web240) from the system 250 and sub-process of FIGS. 2A and 2B. A fluiddistribution and storage construction or core 105 is applied centrallyover one of the overlap regions Ox of the two sets 211 a, 211 b ofsinusoidal elastic strands. The elongated core 205 is applied andpositioned laterally with the length of the core 205 being deposited onthe web 240 in the cross-machine direction. In this embodiment, the core205 is situated between the upper and lower distributions E11 ofelastics. Simultaneous with or immediately after the application of thecore 205, a material sheet 209 (not shown) is applied over the core 205and the web 240. This material sheet becomes the topsheet in thedisposable absorbent article 101. Additional features such asfree-standing elasticised leg cuffs, fastening tapes and disposal tapesmay be added to the construction at this stage.

In a subsequent step or stage in the process, preferably circular holes204 are punched or cut in the web 240. In this embodiment, the holes 204are punched centrally inside of the elastic annular regions O1, but onthe overlap region Ox. As shown in FIG. 4, the holes 204 are also inlongitudinal alignment with the intersections Ix of the elastic strandsand with the wavelength distance “Y” of the sinusoidal patterns. Thecutting of the holes 204 leads to the provision of the leg openings 104in the disposable absorbent article 101. It is, therefore, an importantrequirement of the disposable absorbent article 101 that the wavelength“Y” of the sinusoidal pattern is equal to the width of the finishedarticle 101.

The next step in the production process entails cutting or severing thecontinuous composite web 240 across the cross-machine direction widthand along cutting lines 431. This end cut can be accomplished by anumber of mechanisms known to those skilled in the art, including a diecutting process or a water-jet cutting process. The position of the endcut is determined relative to the wavelength “Y” of the sinusoidalpattern. Notably, cutting lines 431 bisect each hole 204 and alternatingelastic annular regions O1. The cutting lines 431 are also spaced oneither side of the core 205.

Upon separation, discrete, individual elastic composites 136 are formed.The elastic composite 136 now has a longitudinal (lengthwise) centerlinethat bisects the elongated core 105. Further, the composite 136 has twolateral side edges 106 a, 106 b along the original cutting lines. Theside edges 106 a, 106 b consists of a top segment and a bottom linearsegment. The non-linear cut-out section is positioned intermediate thetwo segments and is intended to form the leg openings. The elasticcomposite 136 also feature half elastic annular regions extending toeach side edge 106 a, 106 b, which were severed by the cutting lines,and complete annular elastic annular regions in the center. The elasticcomposite 136 also has a core 105 situated centrally over the centralelastic annular region.

Finally, the elastic composite 136 is folded along fold line 425 whichcorresponds to the longitudinal axis YY of the web 140. The elasticcomposite 136 in this embodiment is symmetric about this axis YY.Accordingly, when folded, each feature or portion on the bottom halfmatch and cover the exact same feature or portion on the top half. Theresult is the disposable absorbent article 101 in FIG. 4 (and FIG. 1A).In the flat and folded state, the article 101 now displays a quarter ofeach leg 104 hole and a quarter of each half-annular region on the sideedges 106 a, 106 b. To finalize the absorbent pants construction, thematching side edges 106 a, 106 b are sealed (seals 130), while thematching upper-lower edges 102, 103 and the quarter-leg holes are not.The specific manufacturing process for this embodiment employed a high“X” value.

The process described with reference to FIGS. 2-4 is one example of theprocess of making the inventive absorbent article. It is not requiredthat the steps described are completed in the order described. It ispossible, and may in some circumstances be preferred, that the steps arecompleted in a different order or that some of the steps may becompleted simultaneously

FIG. 5 is a simplified representation and schematic illustrating a web540 of elastic composite, as well as a method or process of making theelastic composite web 540 and an absorbent article, all according to analternate embodiment of the invention. The illustration provides thelatter or downstream stages of the process, after introduction andapplication of sets 510 a, 511A, 511 b, 510 b of elastics. Downstream ofthe nip roller (not shown), the elastic composite web 540 generallyconsists of two or three layers of sheet material and the desiredelastic patterns and elastic annular distributions for the waist regionand the crotch region. In this embodiment, the two variabledistributions 511 a, 511 b of elastics trace a pattern and period thatconsists of a large (wide) elastic annular region O1 and an overlapregion Ox′ bounded therein and a small (close) elastic annular region O3and its overlap region Ox.″

In a downstream stage, a desired absorbent core section 505 is appliedonto the elastic composite web 540, over the close elastic annularregion O3. Then, a material sheet layer (of topsheet) is applied overthe elastic composite web and the core 505, to provide an enhancedelastic composite web 540 having all of the major components desired ofthe inventive absorbent article. At this step, the elastic composite web540 may be described as a web of elastic composite bodies. In one aspectof this embodiment of the invention, the resultant elastic composite web540 is folded about the longitudinal centerline YY. As shown in FIG. 5,this folding step may be accomplished by diverting the conveyor runabout 90 degrees and such that one half of the elastic composite web 540also rotates 180 degrees onto itself. The result is a 90 degree turn atwhich one half of the longitudinally extending web 540 folds over andmatches its mirror image. The folded web 540 reveals a series ofone-half sections of the wide annular regions O3. Using a conventionalpuncher or cutter, leg holes 504 (or more particularly, half of the legholes) may be punched out of the elastic composite web 540 at a locationwithin the wide overlap region Ox′ and in between core sections 504. Inthis embodiment, this semi-circle cut is made at the upper edge of thefolded elastic composite web.

Furthermore, a sealing bond or line 530 is applied from the leg hole 504towards the side edge, thereby describing the boundaries of a unitaryelastic composite body 536 according to the invention. Preferably,sealing is achieved by ultrasonic bonding, thermal bonding, and thelike. Finally, discrete units 536 of the elastic composite web 540 maybe severed by cutting through the wide sealing or bonding line 530. Infurther embodiments, the sealing and cutting steps may be performedsimultaneously. The result is an elastic composite web in the form oftraining pants, according to the invention.

Now turning to the alternative illustration and schematic of FIG. 6, analternative system 650 and method of making the disposable absorbentarticle utilizes a few different steps and sequences. A first materialsheet 612 is conveyed separately by conventional means. Pre-tensionedelastics 610 (for the upper waist regions) are applied on the sheet 612,preferably near the side edges, as previously described. The resultingelastic composite 640 is then conveyed toward and by conveying means617. Two sets 611 a, 611 b of elastics are also moved and conveyedtoward the conveying means 617, utilizing elastic guides 616 a, 616 b.As before, the elastic guides 616 a, 616 b vary the lateral position ofthe set 211 a, 211 b of elastics in accordance with a periodic functionand to elicit a preferred pattern. Thus, the elastic composite web 640meets the two sets 611 a, 611 b of variable elastics at nip roller 618,thereby enhancing the original web 640 with preferred distributions ofelastics. These preferred distributions include a series of annularregions, as in earlier-described embodiments.

Furthermore, a separate combination web 609 is applied on the elasticcomposite web 640 by a second nip roller 618. This subsequentapplication includes incorporation of a web of sheet material upon whichcore materials are already intermittently deposited, as shown in FIG. 6.The resulting output of the second nip roller 618 is an elasticcomposite web 640 having two material sheets and two sets of variableelastics and two sets of mutually parallel pre-tensioned elastics,similar to the outputs of the systems and processes of FIGS. 2A, 2B.

FIGS. 7-9 illustrate further embodiments of the elastic composite websand distribution that can be achieved by and/or utilized in the presentinvention, wherein like reference numerals are used to indicate likeelements. Referring first to FIG. 7, the elastic composite web 740includes an upper or backsheet material sheet (not shown) 712, a lowermaterial sheet (not shown), but directly underlying the upper sheet 712and multiple distributions of elastic strands. A distribution of elasticstrands 710 a, 710 b is provided along each of the upper and lower edges702, 703 of the web 740. These distributions ultimately make up theelastic annular region about the waist opening. Between these twodistributions, two distributions 711 a, 711 b of variable elastics areprovided (for the lower waist, crotch and leg regions). As in FIG. 3,these variably positioned elastic strands are distributed by means ofthe periodic, lateral motion of the elastic guides in FIG. 2, preferablyto elicit a sinusoidal pattern. The first set 711 a of elastics isdistributed in a first sinusoidal pattern and are overlapped with theother set 711 b of elastics distributed in a second sinusoidal pattern.In this exemplary embodiment, the first and second sinusoidal patternsare mirror images of each other. In this embodiment the degree ofoverlap “X” of the two elastic patterns is much smaller than thatdescribed in the embodiments relating to FIGS. 3 and 4. The resultantabsorbent article made from this type of elastic distribution isdescribed in FIG. 7, and features a greater amount of elastic materialin the crotch region and less elastic material in a mid waist region.

FIG. 8 illustrates an alternate elastic composite web 840, wherein thedegree of overlap or value of “X” is substantially zero or thereabout.An illustration of the absorbent article 801 utilizing this elasticdistribution pattern and an elastic composite body 836 from severed fromthe web 840 is shown in FIG. 8A. The article 801 does not feature acrotch region 834 that is as broadly elasticized as that of theabsorbent article 701 in FIG. 7.

FIG. 9 illustrates yet another, further embodiment of an elasticcomposite web 940 according to the present invention. This alternatecomposite web 940 employs an alternate variable distribution 911 a, 911b of elastics. Specifically in this embodiment, the variable set 911 a,911 b of elastic strands are distributed in a pattern in which the twosets do not overlap. In this example, the value of “X” is said to benegative. Although the patterns do not provide a series of completelyannular elastic regions, the value of “X” is maintained sufficientlysmall so as to approximate a complete annular region, i.e., asubstantially annular elastic region. An illustration of the absorbentarticle 901 utilizing such an elastic distribution and substantiallyannular elastic regions is illustrated in FIG. 9A. By beingsubstantially annular, the elastics about the waist opening and legopening occupy more than 85% to 95% of the complete circle, and thus,the elasticity about the opening is practically continuous andsubstantially complete.

FIGS. 11A and 11B illustrate yet another elastic composite anddisposable absorbent according to the present invention. The elasticcomposite is similar to that provided in FIGS. 8 and 8A. The overlapregion dimension “X” has a value of zero, in that the two distributions1111 a, 1111 b meet but do not completely cross. Instead, the twoelastic distributions 1111 a, 1111 b form a broad, somewhat elongatedconcentration of elasticity at the center of the composite 1136. In theresulting disposable absorbent article, this feature translates to aconcentration of all round elasticity in the crotch region 1134. FIGS.11A and 11B are also provided to show exemplary dimensions of an elasticcomposite of the invention. The Figures also show preferred locations ofcertain element of the elastic composite 1136. For example, the core1105 in this embodiment is located centrally over the concentration ofelasticity discussed above, but is cut at a width that approximates thelength of the elastic concentration discussed above.

FIGS. 11A and 11B also illustrate two stages in an alternative method ofmaking a disposable absorbent article according to the invention. FIG.11A reveals a unitary elastic composite body 1136 that could have beenfreshly severed from a web of elastic composite, according to theinvention Unlike earlier described finished elastic composites, theelastic composite 1136 has not had holes or sections cut therefrom (forlater-formed leg openings). Instead, the elastic composite 1136 isfolded in its full rectangular frame about longitudinal axis YY. Thefolded elastic composite 1136 then features quarter sections of the legholes 1104 that may be cut or stamped out. Thereafter, the side edges1106 may be sealed to form the leg openings of the absorbent trainingpants, according to the invention.

In the illustration of FIG. 12A, another alternative elastic compositeweb 1240 is shown exhibiting a dual elastic distribution patterns (E10,E11). Among other things, the variable elastic distributions E11 featurea broader and more block-like shape to its large annular regions Ox′,rather than the smoother, more rounded shape of earlier-depicted annularregions. FIG. 12B is a graphical diagram of a periodic function andpattern reflecting directive lateral motion by elastic guides to producethe variable elastic distribution patterns E11 on the elastic compositeweb of FIG. 12A. The graph reveals a relation characterized by a steep(almost abrupt) travel from a minimum displacement position (D1) tomaximum displacement position (D2) over a half-period (½P), as well asthe return to minimum displacement position (D1) over the secondhalf-period (½P). This is reflected in the steep or abrupt angle of theelastic distribution E11 in FIG. 12A, as well as the necessarily tightconcentration of the elastics during between the troughs and summits.The graph also reveals slight stall or levelling off of the elasticguide upon reaching the maximum or minimum displacement position. Thisfeature is reflected by a somewhat flat area or plateau at each of thetrough and summit of the elastics distributions E11. This patternfeature differs from the gradual, more rounded troughs or summits inearlier described elastic distribution patterns.

Accordingly, the absorbent article formed from an elastic composite ofthe web 1240 features a thinner, denser elastic annular region about theleg openings. Elasticity is more concentrated on the inside portion ofthe leg opening near and around the crotch region, as opposed to thearea engaging the top of the thigh.

The flow chart 1300 of FIG. 13 illustrates an exemplary and preferredprocess of making the elasticized absorbent pants in FIG. 1. Thispreferred process corresponds substantially with the method of makingthe elastic composite which as described in respect to FIG. 5. Theprocess commences with applying multiple distributions of elastics on amoving material sheet to form a moving web of an elastic composite (step1361). Then, each of a core section and a second material sheet isperiodically applied onto the moving web to define a finished web ofdiscrete elastic composite bodies (steps 1362, 1363). In subsequentsteps, discrete absorbent pants articles are shaped from the finishedweb. In the preferred shaping steps, a bottom half portion and a tophalf portion of the web and composite body are joined. More preferably,the elastic composite web is folded along a longitudinal centerline(step 1364). In this specific embodiment, a section of the folded web isperiodically cut-out (step 1365), thereby periodically providing cut-outsections between core sections and in between elastic distributions.Next, the two half portions are sealed along or to create two laterallyextending seal lines (step 1366), thereby preferably substantiallyjoining multiple elastic distributions on one half portion with elasticdistributions on the other half portion and creating a waist opening andpair of leg openings Finally, elasticized absorbent articles areseparated from the web by severing the lateral side lines (step 1367).Most preferably, the sealing and severing steps immediately produceelastic absorbent pants having a waist opening, pair of leg openings,and multiple substantially continuous elastic distributions extendingthrough two lateral seal lines and creating annular elastic regionsabout the waist opening and the leg openings.

The flow chart 1400 of FIG. 14 describes, more generally, the basicsteps in a method of making an elastic composite web having multipleelastic distribution patterns thereon, according to the presentinvention. Such an elastic composite web is ultimately configured suchthat elastic composite bodies of absorbent pants may be separated fromthe web. The preferred method commences with the step of applyingmultiple continuous distributions of elastics on a moving web ofmaterial sheet to form a web of elastic composite moving in thelongitudinal or machine direction, the distributions generally extendingin the machine direction (Step 1461). The method further entailsperiodically applying a core section on the moving elastic composite web(step 1462). Then, a top material sheet is continuously applied on theweb including the core sections (step 1463). In the step of applyingcontinuous distributions of elastics, at least two periodicdistributions of elastics are established on the moving web by varyingthe lateral position of the distribution of elastics as thedistributions are advanced in the machine direction toward the movingweb of elastic composite (sub-step 1461A). In further embodiments, thestep of applying the continuous distributions may include periodicallyvarying the lateral position of the elastic distribution prior toengagement with the material sheet and further yet, periodically varyingthe lateral position to establish two sinusoidal patterns on the movingweb of elastic composite.

Asymmetric Leg Cutouts

FIG. 4A is a simplified representation of a web-based process of makinga disposable absorbent article 101′ according to the present invention(wherein like elements are referred to using like reference numerals). Avariation of the process described in respect to FIGS. 2-4, this processmay be employed to produce a modified disposable absorbent article 101′.This alternate process is particularly suited to making an modifiedpants product 101′ having fitted leg openings 104′. FIG. 4A shows themoving web 240′ of elasticized composite bodies 136′ from which adisposable absorbent article 101′ is derived. As described previously,the leg openings 104′ are formed subsequent to the folding step byjoining two linear segments 106 a′, 106 b′ of the side edges of theelasticized composite body 136′ and then sealing the union. The freenon-linear cutout section (between the linear segments 106 a′, 106 b′)of the side edge substantially connect to form the leg openings 104′. Inthe finished absorbent pants product 101′, each leg openings 104′ may bedescribed as having a front portion that is larger and extends furtherand arches higher than the back portion (e.g., as shown with theabsorbent pants 101′ in FIG. 4A). Thus, the front portion of the legopening 104′ rides higher on the thigh of the user than the backportion. In certain designs of the pants product 101′, the asymmetric oruneven leg opening 104′ enhances fit and comfort around the front thigharea of the user. This reduction in excess material on the front part ofthe pants, which is relatively flatter and less rounded than the backpart when the pants are worn, allows for more room and discouragesbunching and pinching on the front. The back portion of the leg holefits lower and more snugly about the back of the wearer and, thus,preserves sealability and loading capacity in the back of the pantsproduct.

As illustrated in FIG. 4A, the alternative pants product 101′ is, insimplest terms, achieved by varying the leg hole cutout step.Specifically, holes 204′ are punched out or otherwise cut into the web240′ at a position offset from the longitudinal centerline YY. With thecircular cutouts in the previously described process, the cutouts areplaced symmetrically about the longitudinal centerline YY and thus,about the fold line 425. For the exemplary pants product 101′, acircular or ellipitical cutout 204′ is placed asymmetrically about thelongitudinal centerline YY and lower relative to the longitudinalcenterline. In FIG. 4A, the cutouts 204′ provide an arc region below thelongitudinal axis YY that is larger (in arc length and area) than thearc region provided above the longitudinal centerline YY. In the foldingstep, the web composite 240′ is folded along the fold line 425, whichcorresponds to the longitudinal centerline YY, to form the leg opening104′. As a result, the front part of the leg hole 104′ is roomier andrides higher on the thigh of the wearer.

As with the previously described embodiments, periodic elasticdistributions of elastic are directed about the leg cutouts 204′ and legopenings 104′. The elastic distributions 111′ form elastic annularregions about the leg holes 104′, thereby enhancing fit and support. Inthis particular embodiment, the elastic distributions 111′ that closelytraverse the top of the leg cutouts exhibit a flatter pattern than theother elastic distribution.

In another variation, the leg cutout may be employed in a shape otherthan a circle. For example, an elliptical cutout may be employed to forma leg opening in the pants product that is sleeker or narrower than thatresulting from a circular cutout. In either variation, a curvilinearelastic distribution may be applied to accommodate the leg cutouts andultimately, provide an annular elastic region about each leg opening infinished pants product. The inventive method of elasticizing a movingweb substrate is, therefore, shown to be well suited for providingannular elastic regions about leg openings of different shapes andlocations on the web.

Shorts-Like Elasticized Pants Product

With reference to FIGS. 15A-15B and 16A-16B, a variation in thepreviously described method of making an absorbent pants productaccording to the invention will now be discussed. In this embodiment,the steps of applying distributions of elastics and providing legcutouts in a moving web 1540 are modified to produce an alternative ormodified pants product 1501. Two exemplary pants products 1501, 1601 aredepicted in FIGS. 15A and 16A. The pants products feature a flatter ormore horizontal leg opening 1504, 1604, which may be described by a legopening angle θ between the vertical centerline VV of the pants and aplane TT tangent to the leg opening. As compared to the previouslydescribed pants products, the leg opening angle θ in these embodimentsare rotated outward and closer to 90 degrees. In the pants product ofFIG. 1, the angle θ is close to about 45 degrees, whereas each of thepants product of FIGS. 15A and 16A features a leg opening angle that maybe greater than about 75 to 80 degrees.

The simplified illustration of a moving web substrate in FIG. 15B showsthe modifications to the elastic distributions 1511 a, 1511 b and theleg cutouts 1504 required in a process of making the pants product 1501.Firstly, the leg cutouts 1504 are not circular but are in the shape ofrelatively flat ellipticals. The short diameter of the elliptical issubstantially less than the long diameter, creating a cutout 1504 thatis more slit-like than a circular hole. Secondly, the elasticdistributions 1511 a, 1511 b provided about the leg cutout 1504 isflatter and less sinusoidal. In this exemplary embodiment, the twoelastic distributions 1511 a, 1511 b do not cross or overlap. The upperdistribution of elastics 1511 a stays above the longitudinal centerlineYY and the lower elastic distributions 1511 b is maintained below. Theelastic distributions 1511 a, 1511 b are not completely flat, butfeature a slight curvature while traversing the periphery of the legcutout 1504. In any event, an annular elastic region about the legopening 1504 is achieved.

Now referring to the simplified illustration of a moving web 1640 inFIG. 16B, the two sets of elastic distributions 1611 a, 1611 b intersectto create a more sinusoidal pattern around the area of the core 1605 orat least, a periodic pattern featuring alternating sections of highamplitude and low amplitude. In the area where the leg cutout 1604 is tobe provided, however, the distribution of elastics is flatter andclosely follows the elliptical slits 1604 in the web 1640. The intendedcrotch regions of the web 1640 are traversed by a pair of elasticdistributions 1611 a, 1611 b of high amplitude. The elastics pass overand are concentrated on the upper extent and the lower extent of eachelongated core placement. In this way, the elastics generally proximatethe outside periphery of the core 1605.

In either pants product, the resultant leg opening is described as beingsubstantially circumferentially elasticized and featuring an elasticannular region. When worn, the annular elastic region substantiallyencircles the thigh of the user. In one respect, the pants product ofFIGS. 15A and 16A are attributed with characteristics more akin toelasticated shorts (e.g., bike shorts). In this way, the pants productis provided with an encircling elasticized support about the thigh ofthe user. This circumferential support is generally more horizontal andfocused lower than that of the leg hole of the pants product 101 in FIG.1A. The circumferential engagement between each elasticized leg openingand the thigh of the wearer serves as an anchor point for the absorbentpants product. Together with the circumferential elastic annular regionabout the waist, the elastic annular regions around the leg openingactively seal the pants product about the body of the wearer.Importantly, support provided by the elasticized leg holes also providesenhanced support in the crotch region and core area of the pantsproduct.

Gapping in the Elastic Distributions

In yet another aspect of the present invention, the system and method ofmaking an elasticized absorbent product includes a modified step ofapplying multiple distributions of elastics on the moving web. Asdescribed previously, in a preferred process, continuous distributionsof elastics are applied generally in the machine direction. Thisincludes applying and establishing at least two periodic or curvilineardistributions (generally in the machine direction) of elastics on themoving web by varying the lateral position of the elastics as theelastic distributions are advanced in the machine direction. Further tothis step, continuous distributions of elastics may be applied toestablish generally machine-directed distributions of elastic on eachelastic composite body which have intermittent gaps (in the elastics).That is, a continuous, generally machine-directed distribution ofelastic is applied, but the elastic strand on the finished composite weband on the final product is effectively segmented due to theintermittent gaps.

The locations of the gaps on the web are predetermined to correspondwith desired gaps or absence of elastics in the final pants product. Insome applications, the gap may be sufficiently wide to effectivelyde-elasticize the target area and in other applications, will beminimized to maintain continuity in the annular regions of elasticity inthe final absorbent product. In one exemplary process, gaps in theelastic distributions are provided at locations on the web thatcorrespond to the side edges of the pants product, whereupon the sideseal or seams are formed. In yet another embodiment, gaps in the elasticdistributions are located to coincide with the core location near thecentral or crotch region of the absorbent article. In this embodiment,it may be desired to disengage the core from the elastics and provide arelatively stable and unbiased core structure, or allow undisturbedplacement of additional elements onto the core surfaces.

To exemplify these variations in the process and in the absorbentproduct of the invention, FIG. 17 provides a simplified illustrationcorresponding to the illustrations of FIGS. 2A-B and 4, with an elasticcutting or gapping step incorporated into the process. FIG. 17 shows theweb 1740 of elastic composite delivered by rollers 1701 and 1702 and anelastic composite body 1736 severed from the web 1740. As shown in themoving elastic composite web 1740, multiple continuous distributions ofelastics 1710 a, 1710 b, 1711 a, 1711 b are applied on the moving webwith the two middle periodic elastic distributions 1711 a, 1711 boverlapping along the central portion of the web 1740. In thisembodiment of the invention, the absorbent product 1701 is provided withgaps U1 along the proximity of the side edges or seams. The removal ofelastics in this area provides a flat and consistent surface that maybetter accommodate a sealing operation, such as ultrasonic bonding orheat treatment. Furthermore, the flatter and more consistent surface,without shirring, may be deemed more aesthetically appealing in someproduct designs. In some applications, the gaps U1 will be minimized toensure continuity of the annular elastic regions discussed previously.

As described previously, the distributions of elastics 1710 a, 1710 b,1711 a, 1711 b may be applied on a nonwoven web of backsheet material asboth input feeds engage a form roller 1701. Then, a web of intermediatenonwoven meets the form roller 1701 and is applied over the elastics toform a subsequent web featuring multiple continuous distributions ofelastics sandwiched between two nonwoven webs. Preferably, the elasticsare subsequently cut or gapped by engagement of the form roller 1701with a cutter roller 1730, and while retained in this sandwich andbefore the elasticized web meets the input feed of core section(s). Suchlamination of the elastics helps to hold the elastics in place duringand after cutting. In this technique, the elastics may be severed bypressing a blade of the cutter roller 1730 through the intermediatenonwoven layer and against the roller 1701, preferably with minimalpuncture of the backsheet layer.

In one suitable arrangement, the form roller 1701 engages a secondroller 1730 equipped with a set of blades or cutters 1731 for cuttingthe elastics, as known in the art. One suitable arrangement may be foundin the specification of U.S. Pat. No. 4,525,229 (see e.g., FIG. 2). Forthe exemplary pants product design, a first pair of blades or cutters1731 is spaced axially apart and has a lateral width sufficient toengage the extent of waist elastics. The cutters 1731 are, therefore,positioned near the ends of the cutter roller so as to correspond to thelateral locations of the waist elastic distributions on the web. In thedepicted embodiment, the cutters 1731 are sufficiently axially long toreach and sever the middle elastic distributions 1711 a, 1711 as well aswaist elastics 1710 a, 1710 b. In further embodiments, two independentpairs of cutters may be employed, however, to minimize puncture of thenonwoven layers. A second pair of similarly spaced apart cutters (notshown) is provided just several degrees from the first pair of cutters1731. The spacing between the two pairs is selected to correspond to thedesired gap U1 on the moving web 1740 and to proximate the width(actually twice the width) of the desired side seam.

As known in the art, the speed of the cutter roller 1730 is synchronizedwith the rotation of the form roller 1701 so as to properly articulatethe required gapping. The cutters 1731 may further register with ananvil(s) provided on the form roller 1701 to make the desired cuts. Inthe depicted embodiment, the circumference of the form roller 1701 maycorrespond to four or five times the width of one pants product on theweb 1740. Thus, the form roller 1701 is equipped with a number ofproperly spaced anvils, and the cutter roller 1730 will rotate at a ratethat causes the cutters 1731 to engage the anvils.

In yet a further embodiment, the pants product may be freed of elasticsin and around the location of the core 1705. A desired gap U2 has awidth that approximates the width of the core 1705. Such a modificationmay be desired to provide stability and consistency to the core,including preventing any bunching of the core as well as the adjacentnonwoven sheet(s). In this particular design, only the two middledistributions of elastics 1711 a, 1711 b are gapped, as the waistelastics 1710 a, 1710 b do not encroach upon the intended area of thecore 1705. The same roller 1730 as the one cutting the waist elastics,or another cutter roller, may be provided to engage the form roller 1701and place intermittent gaps U2 in the two sets 1711 a, 1711 b ofperiodic or curvilinear elastic distributions. As the targetdistributions of elastics are typically closer to the center of themoving web, the cutters and matching anvils are also located near thecenter of the cutter roller 1730 and form roller 1701, respectively. Tomake the desired cut, two pairs of axially spaced apart cutters may beused or one longer cutter that extends from one elastic distribution tothe other. Preferably, two successive pairs of cutters are provided thatare spaced part in correspondence with the gap in the elastics.

Elasticized or Profiled Core Structures

In the systems depicted in each of FIGS. 2 and 6, as well as thatdescribed in respect to the process illustrated through FIGS. 3, 4 and5, the core is delivered intermittently to the moving web pre-cut andoriented generally perpendicularly to the longitudinally movingdirection of the moving web. As specifically shown in each of FIGS. 4and 5, the pre-cut core is delivered on the web extending lengthwisebetween the longitudinal edges of the web, but in between each side edge(or severing line) of the elasticized composite. The core is, therefore,deposited in correspondence with its final location and orientation inthe finished disposable absorbent product.

In many of the embodiments described herein, the inventive process isemployed to apply a distribution of elastics across the width of eachabsorbent product, including over the core. The engagement orinteraction between the elastics and the core may impart elasticity tothe core, as required or desired by the design of the absorbent product.The resulting elasticized core may feature aesthetic and functionalcharacteristics due to its elasticized regions. The benefits ofelasticized core configurations have been discussed, for example, inU.S. Patent Application Publication No. US2011/0130736 A1, specificallyFIGS. 6-9 in that publication (which application is assigned to anAssignee common with the Assignee of the present application andinclude, as inventors, one or more of the inventors named for thepresent application). One of the Figures is reproduced herein as FIG. 18to illustrate an elasticated core structure 1801 (in a contracted state)achievable with the present inventive system and process. The coreconfiguration includes a plurality of elastic distribution 1810 appliedlaterally in machine direction, and generally centrally on the movingweb and across the core 1812. This previous patent applicationpublication and specifically FIGS. 6-9 of the publication, and thedescriptions accompanying those Figures, are incorporated herein forbackground purposes and made a part of the present disclosure. Thecommon element in these referenced elasticized core designs is thatelastics 1811 are directed and applied onto or proximate the core 1812in the direction lateral to the lengthwise direction of the core 1812.In the present system and process, the application of elastics in themachine direction and centrally on the moving web, and the intermittentdeposition of the core onto the web substrate in its ultimate positionand orientation facilitate the provision of such an elasticized core.Moreover, the presently described system and process allow forvariations in the elastic pattern applied to the core, including aplurality of different distributions or sets of elastics, spacingbetween the elastics, linear and/or curvilinear distribution patterns,including sinusoidal and other shapes.

The present system and process also allows for the cutting or gapping ofthe elastic distributions on the moving web and in the finisheddisposable absorbent product. In one embodiment, other curvilinear orperiodic designs may be employed to distribute elastics about andproximate the periphery of the core and to encourage a pocket or cupshape in the core. The overlap of the two elastic distributions createsan annular elastic region along the periphery of the core, which canadvantageously act as a type of O-ring seal. Such an elasticized O-ringmay be designed in alignment with the user's bottom to improveabsorption and retention. The elastic distribution shown in FIGS. 3-4and 7-7A are two configurations suited for establishing such an annularelastic region and o-ring seal about the area of the core.

Several further variations in the process may be employed to engage theelastic distributions with the core. As discussed above, the elastic maynot be applied directly to the core. For example, the elastic may beapplied to the backsheet and situated between the backsheet and a secondsheet or nonwoven. The resultant composite is then bonded with the core.With this composite, and specifically the backsheet directly engagingand connected with the core, the elastics within the backsheet compositeact upon the core to create the desired elasticized and/or profiledshape. In another exemplary variation, the elastic may be applied to thebacksheet and then the core is applied directly on top of the elastics(e.g., without an intermediate sheet). In any case, the elastic andsheet materials, and the core, are brought together on the form roller,and adhesive may be applied to the material sheets and elastics justbefore arrival at the forming roller.

In several of the core designs of FIGS. 6 and 7 in the referenced U.S.Patent Application Publication No. US2011/0130736 A1, the elastics areapplied laterally and centrally on a rectangular core or in specificembodiments, in both or each of two overlapping cores. Elastication ofthe absorbent core structure, upon release of tension in the elastics,creates a narrowed central region of the elasticized core, which, asdescribed in the referenced publication provides aesthetic andfunctional benefits in the absorbent product. In further embodiments,the spacing or pitch between successive elastics may be designed so asto create more of a concave narrowed central region. This may beachieved, for example, by placing a higher concentration of elasticsalong the center and a lower concentration away from the center (seee.g., FIGS. 7C-D in the referenced publication). The elastics may bestrategically placed between a stack of cores and other materials toprovide the profiled core configurations in FIG. 8 (of the referencedpublication) as well as the corrugated configuration of FIG. 9 (in thereferenced publication).

Elastic Composite Web Forming Mill

FIG. 10 is provided as a simplified physical representation of a system1050 according to the invention, and more specifically, an elasticcomposite web forming or joining mill 1000 of the system. The area (orregion) inside the dashed box represents, in one aspect of the inventivesystem 1050, a centralized conglomeration of web components and systemmachine components, from which the desired web 1021 of discrete elasticcomposite bodies are outputted. The inventive system 1050 may bedescribed as comprising a plurality of feed lines that converge on thejoining mill 1000 in a predetermined manner to produce the predeterminedmoving web substrate 1021. The input feed lines are managed to direct acomponent of the product at a rate, speed, orientation, and lateralplacement required of the web substrate product. Some input feed linesmay be associated with “cut and place” units that intermittently apply adiscrete unit of material to the moving web. Furthermore, the input feedlines are managed to converge and engage other input feed lines in thedesired sequence and rate required.

With the system 1050 in FIG. 10, each of the elements of the websubstrate is preferably applied to the mill 1000 linearly or inline inthe machine direction. Accordingly, all feed lines and output lines canapproach the mill 1000 from the right or left, or the top of the mill1000, but within a lateral window not exceeding the axial length of theform roller 1001 (and, in some micro-applications, not substantiallywider than the width of the web substrate 1021 a). This physicalcharacteristic of the system 1050 promotes manageability and flexibilityin the process, including the ability to modify the properties of thefinished absorbent product. The inventive system, and more particularlythe mill 1000, also displays a small footprint. The mill 1000 also lendsitself to being packaged as a modular, self-contained unit.

In one embodiment of the invention, a web substrate product 1021 a isoutputted by the mill 1000 as shown in the lateral cross section of FIG.10A. Upon output from the mill 1000, the moving web substrate 1021 acomprises a layer of topsheet TS on the bottom, an AD (acquisition anddistribution) layer above the topsheet TS, and a series of individual,elongated cores C above the AD layer AD. Above this, a sandwich isprovided of an intermediate nonwoven layer NW, a layer of backsheet BS,and various elastic distributions E therebetween. Directional arrows inFIG. 10 indicate the direction toward which the composite web 1021 a isfolded. As shown, the web 1021 a is folded such that the topsheet layerTS rotates toward itself and is ultimately positioned on the inside ofthe folded web. In the finished absorbent article as worn, the topsheetTS is placed adjacent the body of the wearer.

After emerging from the mill 1000, the web substrate 1021 a may befolded, sealed, and cut to produce the disposable absorbent article.These subsequent steps are considered post-joining steps that areimplemented after delivery or output of the web 1021 a. The folding stepis performed at a folding station 1022 comprising of angular directionalbars that are located immediately forward of rollers 1001, 1002. Thefolding station 1022 directs the web 1021 to a series of turns thatflips and folds the substrate 1021 a. Once folded, the leg holes are cutout, the side seams are sealed together, and then, the web substrate issevered along the seams (to produce discrete pants products). Thesesteps have been discussed in respect to FIGS. 4 and 5, for example.Additional, pre-packaging steps may also be employed after the sealingand severing steps. In alternative embodiments, the step of cutting orpunching the leg cutouts may be provided before the folding station 1022and immediately after delivery of the web substrate output 1021 a.

It should be noted that the post-joining steps may be modified so as toprovide for a diaper product, as opposed to a pants product. In such avariation, the side seam sealing step may be eliminated. In thisrespect, the web substrate output may only require the severing step toproduct discrete diaper products. In a further variation of the system,process, and product that is derived from the inventive system andprocess, the web substrate outputted by the joining mill may be foldedin the reverse direction to produce a modified pants product or diaper.Such a product objective may require modifications to the input feedlines to the joining mill, as further described below.

Referring now to FIG. 10 and well as FIG. 10A, several stages of thejoining process are described as a sequence of joining variouscomponents of the web substrate 1021 a. The primary components of themill are a main or forming roller 1001 and a corresponding secondaryroller 1002. As shown in FIG. 10, an input feed 1011 of backsheetmaterial is engaged by the forming roller 1001 as well as thedistributions 1012 of waist elastics and distributions 1001, 1003 ofcurvilinear elastics (as previously described in more detail in respectto FIGS. 2A and 2B). The moving web of elastics applied to the backsheetis then engaged from above by an input feed 1014 of intermediatenonwoven. This engagement sandwiches the elastics within the backsheetand intermediate nonwoven. In further embodiments, a cutter roller maybe added to engage the form roller and to selectively cut one or more ofthe elastic distributions sandwiched by the backsheet and intermediatenonwoven.

The resultant elasticized web then engages the input feed 1016 of spacedapart and laterally oriented cores. As described previously, the coresare spaced in correspondence with a central position on the final pantsproduct and in alignment with the longitudinal centerline of the movingwebs and the forming roller 1001. The cores are preferably deliveredpre-cut in an elongated rectangular form that is lengthwise to thelongitudinal or machine direction. A cutting roller machine 1027 isprovided upstream of the rollers 1001, 1002 and receives a continuousfeed of sheet core material from a supply roll 1029. Preferably, asecond input feed 1016 of a second core or an ADL layer is directed atopand upon the resultant elasticized composite (with core). In thisinstance, an input feed 1017 of the topsheet engages the elasticcomposite (with cores) to provide a topsheet layer over the corematerial(s). The resultant product is a moving web substrate 1021 of anelasticized absorbent composite that may be further processed to producea pants product or a diaper product.

In this system configuration, the web substrate 1021 a is delivered withthe backsheet BS on top and the topsheet TS on the bottom. Thecontinuous web 1021 a is the preferably passed to the folding station1022, which effectively flips and folds the web 1021 a. From there, theside seams of the web 1021 a may be sealed and then severed, to producediscrete elastic composite bodies.

Reversed Elastic Composite

In a further embodiment, an alternative disposable absorbent product isproduced by the system and process by modifying the input feed lines tothe joining mill 1000. Such an alternative moving web substrate 1021 bof elasticized composite bodies is depicted in FIG. 10B in lateralcross-section. The moving web 1021 b outputted by the joining mill 1021provides a topsheet layer TS as a top layer and multiple distributionsof elastics E sandwiched between the topsheet layer TS and anintermediate nonwoven layer NW. The core C, the ADL layer AD, and thebacksheet layer BS fill out the rest of the elastic composite. Referringto FIG. 10, such a composite web 1021 b may be achieved by switching,for example, the topsheet feed 1017 with a backsheet source and perhaps,as necessary switching the ADL and core input feed sources. Finally, theresultant web substrate is folded in the reverse direction (see folddirectional arrows) such that the elastic distributions E are inside ofthe core C. By placing the elastics closer to the user, the topsheet TSis drawn closer to and about the body of the wearer and the elasticizedcomposite 1021 b will tend to support and accommodate the contour of thewearer's body. The improved engagement of the topsheet TS about thewearer not only enhances fit, but the topsheet TS is better positionedto prevent leakage. In further embodiments, the inventive process may beemployed to apply sinusoidal or other curvilinear elastic distributionsabout the periphery of the core, thereby creating an elastized pocketabout the topsheet/intermediate nonwoven sub-composite or the core. Theincorporation of such an upwardly biased pocket may also be conducive tothe use of one or more central apertures for disposal into the spacebetween the core and the topsheet/intermediate nonwoven.

The foregoing description of the present invention has been presentedfor purposes of illustration and description. It is to be noted that thedescription is not intended to limit the invention to the variousarticles, products, systems, apparatus, and processes disclosed herein.Various aspects of the invention as described above may be applicable toother types of disposable absorbent articles and garments, and processesfor making the same. For example, the elastic composite described above,may be incorporated in other disposable absorbent garments such asdiapers, etc. or in other areas or as other components of the garment.Moreover, the processes described by FIGS. 1-18 may be utilized toproduce compositions, garments and articles other than those describedherein. Such variations of the invention will become apparent to oneskilled in the relevant consumer products are provided with the presentdisclosure. Consequently, variations and modifications commensurate withthe above teachings, and the skill and knowledge of the relevant art,are within the scope of the present invention. The embodiments describedand illustrated herein are further intended to explain the best modesfor practicing the invention, and to enable others skilled in the art toutilize the invention and other embodiments and with variousmodifications required by the particular applications or uses of thepresent invention.

What is claimed is:
 1. A disposable absorbent article comprising: atopsheet layer; a backsheet layer; multiple distributions of elasticsdisposed between the topsheet layer and the backsheet layer; and a coredisposed between the toposheet layer and the backsheet layer; whereinthe multiple distributions of elastics include at least two curvilineardistributions of elastics that include a first periodic elasticdistribution and a second periodic elastic distribution, the first andsecond periodic elastic distributions mutually converging at twopositions and spaced apart therebetween, forming alternating annularregions of high amplitude and low amplitude formed by curved sections ofthe first and second periodic elastic distributions, wherein the core ispositioned in a location coincident with an annular region of highamplitude.
 2. The disposable absorbent article of claim 1, wherein themultiple distributions of elastics are disposed between the topsheetlayer and the core.
 3. The disposable absorbent article of claim 1,wherein the periodic elastic distributions each extend continuously froma section of low amplitude, across a section of high amplitude whereinsaid core is placed, to another section of low amplitude.
 4. Thedisposable absorbent article of claim 1, wherein the core is situatedbetween the first and the second curvilinear distribution of elastics.5. The disposable absorbent article of claim 1, wherein the at least twocurvilinear distributions of elastics are disposed about and proximatethe periphery of the core and form a pocket or cup shape in the core. 6.The disposable absorbent article of claim 1, wherein the at least twocurvilinear distributions of elastics are disposed about a periphery ofthe core.
 7. The disposable absorbent article of claim 6, wherein the atleast two curvilinear distributions of elastics form an annular elasticregion along the periphery of the core.
 8. The disposable absorbentarticle of claim 7, wherein the annular elastic region along theperiphery of the core forms an O-ring seal about the core.
 9. Thedisposable absorbent article of claim 6, wherein the at least twocurvilinear distributions of elastics disposed about the periphery ofthe core form an upwardly biased elasticized pocket about the core. 10.The disposable absorbent article of claim 9, further comprising one ormore central apertures into a space between the core and the topsheetlayer and the intermediate nonwoven layer.
 11. The disposable absorbentarticle of claim 1, further comprising an intermediate nonwoven layerdisposed between the topsheet layer and the backsheet layer, wherein themultiple distributions of elastics are sandwiched between the topsheetlayer and the intermediate nonwoven layer, and wherein the core isdisposed between the intermediate nonwoven layer and the backsheetlayer.
 12. The disposable absorbent article of claim 11, wherein the atleast two curvilinear distributions disposed of elastics are disposedabout a periphery of the core and form an upwardly biased elasticizedpocket about the topsheet layer and the intermediate nonwoven layer. 13.The disposable absorbent article of claim 12, further comprising one ormore central apertures into a space between the core and the topsheetlayer and the intermediate nonwoven layer.
 14. The disposable absorbentarticle of claim 11, further comprising an acquisition distributionlayer disposed between the core and the intermediate nonwoven layer. 15.A disposable absorbent article comprising: a topsheet layer; a backsheetlayer; multiple distributions of elastics disposed between the topsheetlayer and the backsheet layer; and a core disposed between the toposheetlayer and the backsheet layer; wherein the multiple distributions ofelastics are disposed between the topsheet layer and the core, andinclude at least two curvilinear distributions of elastics, the at leasttwo curvilinear distributions of elastics forming an annular elasticregion and an upwardly biased elasticized pocket about the core.
 16. Thedisposable absorbent article of claim 15, further comprising anintermediate nonwoven layer disposed between the topsheet layer and thebacksheet layer, wherein the multiple distributions of elastics aresandwiched between the topsheet layer and the intermediate nonwovenlayer, and wherein the core is disposed between the intermediatenonwoven layer and the backsheet layer.
 17. The disposable absorbentarticle of claim 16, further comprising one or more central aperturesinto a space between the core and the topsheet layer and theintermediate nonwoven layer.
 18. A method of making a disposableabsorbent article, the method comprising: conveying a first materialsheet; applying multiple distributions of elastics to the first materialsheet, forming an elastic composite web; applying a core to the elasticcomposite web; applying a second material sheet to the elastic compositeweb including the core; wherein applying the multiple distributions ofelastics includes periodically varying a lateral position of thedistributions of elastics relative to the machine direction of theelastic composite web to establish two curvilinear patterns on theelastic composite web, whereby the two curvilinear patterns includealternating sections of low amplitude and high amplitude; and whereinapplying the core on the elastic composite web includes placing the corein locations of the elastic composite web corresponding to a section ofhigh amplitude, whereby said elastic distributions extend continuouslyfrom a section of low amplitude, across a section of high amplitudewherein said core is placed, to another section of low amplitude. 19.The method of claim 18, wherein the second material sheet is a topsheetlayer of the disposable absorbent article and the first material sheetis a backsheet layer of the disposable absorbent article.
 20. The methodof claim 18, wherein applying the multiple distributions of elastics tothe first material sheet forming the elastic composite web includesforming an upwardly biased elasticized pocket about the core with the atleast two curvilinear distributions of elastics disposed about aperiphery of the core.
 21. The method of claim 18, wherein the at leasttwo curvilinear distributions of elastics form an annular elastic regionalong the periphery of the core.
 22. The method of claim 21, wherein theannular elastic region along the periphery of the core forms an O-ringseal about the core.
 23. The method of claim 18, further comprising,prior to applying the core, applying an intermediate nonwoven layer tothe elastic composite web, wherein the multiple distributions ofelastics are disposed between the intermediate nonwoven layer and thetopsheet layer.
 24. The method of claim 23, wherein applying themultiple distributions of elastics to the first material sheet formingthe elastic composite web includes forming an upwardly biasedelasticized pocket about the topsheet layer and the intermediatenonwoven layer with the at least two curvilinear distributions ofelastics disposed about the periphery of the core.